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Circulating Chiller
A circulating chiller is a device used in laboratories and industrial settings to control the temperature of various equipment or processes. It works by circulating a cooling fluid, typically water or a mixture of water and glycol, through the system to absorb heat and maintain a consistent temperature.
Why Regular Maintenance of Chillers System in Dubai Matters
In Dubai’s climate, where temperatures frequently soar above 40°C, a reliable cooling system is essential. Chillers play a crucial role in keeping residential, commercial, and industrial spaces comfortable and functional. However, even the best chillers system in Dubai can underperform if not maintained regularly. Here’s why consistent upkeep is vital for your cooling system and the benefits it provides.
Ensures Energy Efficiency
Chillers consume a significant amount of energy, and without regular maintenance, their efficiency can drop. Dust, debris, and wear and tear on components cause the system to work harder, consuming more energy. Routine cleaning and servicing help optimize performance, ensuring that your chillers system in Dubai operates at peak efficiency and keeps energy costs manageable.
Prolongs Equipment Lifespan
Neglecting maintenance can lead to unnecessary wear and tear, shortening the lifespan of your system. Simple tasks such as checking refrigerant levels, inspecting coils, and cleaning filters can go a long way in preserving the system. Regular inspections help detect and address minor issues before they escalate, ensuring that your chillers system in Dubai lasts for years without major breakdowns.
Prevents Unexpected Breakdowns
A malfunctioning chiller can disrupt operations, especially in commercial and industrial settings where cooling is critical. Regular maintenance reduces the risk of unexpected failures by identifying potential problems early. This proactive approach minimizes downtime and avoids costly emergency repairs. A well-maintained chillers system in Dubai is a dependable ally during Dubai’s scorching summers.
Maintains Optimal Cooling Performance
Chillers that are not maintained regularly may struggle to provide consistent cooling, especially during peak usage periods. Over time, inefficiencies like clogged coils or low refrigerant levels can reduce cooling capacity. Routine checks ensure that your chillers system in Dubai delivers consistent and reliable performance, keeping indoor environments comfortable regardless of the external temperature.
Chiller Water Treatment Chemicals Manufacturer | Chemtex Speciality Limited
Maintaining chiller systems is crucial for any commercial operation that relies on efficient cooling. Regular maintenance ensures that chillers operate at peak performance, which directly impacts energy efficiency, operational reliability, and cost savings.
According to Chemtex, a leader in water treatment solutions, effective chiller water treatment involves the use of specific chemicals that prevent corrosion, scaling, and bio-fouling. These chemicals work by forming a protective film on metal surfaces, maintaining proper pH levels, and removing dissolved oxygen that can cause corrosion.
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Economizer system
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Use of Glycol in Chiller System
Glycol releases and absorbs huge amount of heat without changing system’s temperature and hence finds its association with chiller system, for process cooling and heating applications. Water, as a coolant, in chillers, possess several kinds of issues such as scaling, corrosion and algal growth. As per this, if glycol is added in water, and pumped through the pipes of a glycol chiller, it manages to slow the freezing rate, even inhibiting bacterial growth within. Glycol is an organic water-miscible antifreeze liquid that is used as a heat transfer fluid which draws away heat, and allows the engine to operate efficiently, with lesser malfunctions and damages to its parts.
A process cooling and heating system provides consistent pressure and temperature to industrial process, ensuring highest grade performance. Owing to glycol’s antifreeze property, it helps in cooling of fluid below boiling temperature in order to complete water condensation. Water is used as coolant in most of the cases but it takes part in rust formation, algal growth, scale deposition, which adversely affects internal metallic chamber. So, adding glycol along with water ensures more heat transfer capability and low freezing point as well as ensures protection. The glycol solution prevents bursting and freezing in cooling system. For most chiller applications, mixture of glycol and water is used for enhanced heat exchange. Two most common areas where glycols are used are chiller cooling system and evaporators.
Glycol chillers are mainly categorized into Ethylene and Propylene chillers, used in chiller machines through HVAC system, as per different end use perspectives. These are closed looped systems where the glycol mixture circulates constantly without coming in contact with outside environment. Since, the system is a closed one, there is a negligible chance for glycol contamination and water loss from evaporation. In Evaporators, the heat exchanger transfers heat between glycol solution and the refrigerant. It works around the flowing glycol that absorbs heat from the refrigerant and passes it away.
Ethylene Glycol has more desirable physical proper ties, specially at lower temperatures. It also possesses superior heat transfer properties due to high boiling point and viscosity. On the other hand, Propylene glycol posses less temperature, contain corrosion inhibitors to enhance heat exchange. Its pH and toxicity are low, so basically Propylene Glycol used in food industry, beer manufacturing, cold shortages and other manufacturing units. Ethylene Glycol has been used in industrial water-cooling system (pharmaceutical industry, cold rolling mills, vegetable oil manufacture and other F&B industry) for its indirect cooling application. Besides this, glycol is anti-oxidising element which needs inhibitors to prevent for long time. Ethylene Glycol is more toxic than Propylene, so it needs to be handled safely. Glycol water coolant mixture from a refrigeration unit in a Glycol chiller funnel linked with thermal heat exchanger piping. It absorbs heat from industrial process, and then warmed the coolant. Theses warmed coolant hence return to refrigeration unit in order to repeat cooling process.
Chemtex Speciality Limited is an eminent supplier of both Ethylene and Propylene Glycol all over India. Also available are its inhibited variants, with coolants, rust inhibitors, and antifoulants, to be used in any automotives, pharmaceuticals, bio-tech, food & beverage, hydraulics, paints, polyester manufacturing, cosmetics, and geo-thermal applications. For more details, please visit https://www.chemtexltd.com/products-and-solutions/heat-transfer-fluid/glycol-antifreeze/. For other information, contact us at [email protected].
Use of Glycol in Chiller system
For other information, contact us at [email protected].
Variable Primary Flow of Water Cooled Chiller System
The advancement in technology for HVAC controls applied to water cooled chiller systems makes it possible to reduce the environmental impact and operating costs.
Chillers are the biggest power consuming equipment in the chiller system but other equipment such as pumps, cooling towers and or dry coolers, Cooling tower fans and other motors should also be considered
A variable flow distribution pumping system to serve the HVAC load is one of the methods to reduce the initial cost and operating cost — depending on the application and the spread area of chilled water load. (speed and pressure modulation is usually accomplished by providing the chilled water pump with a variable frequency drive)
In primary variable flow system, chiller water flow rate is varied in the water cooled chiller depending on the load. This enables to work on higher deltaT unlike lower delta T syndrome happening in traditional Primary + Variable secondary systems. The effect is reduction in the cost of procuring water and pumping load, translating into savings in initial cost and as well as the operating cost.
In primary variable flow systems, evaporator shall be suitable for variable flow operation. i.e. designed to perform proper heat transfer at different water velocities across the tubes.
Generally the flow will be varied between 40% to 100% of the design flow, depending on the load condition. Another important factor to be considered while designing primary variable flow system is that the chilled water flow change rate change should not be more than 2% from the previous flow within 10 Minutes of band. Very fast flow variation to the chiller can lead to operational problems and impact the efficiency of the system and the evaporator as well.
Water flow to the water cooled chiller is to be ensured within the chiller operating limits even during the low load operation. So, we need to employ sophisticated control arrangements for the primary variable flow operation.
The diagram below explains the configuration and working principle of a water cooled chiller’s primary variable system.
Chilled water flow is varied according to field demand.
Flow through each water cooled chiller is monitored and compared against design through a flow meter.
Chilled water pump speed modulates to maintain a set field DP across the water cooled chiller system i.e. between the supply and return header.
As field demand decreases, field DP will increase.
An increase in field DP above set-point will reduce water cooled chiller pump speed and thereby the flow.
A decrease in field DP below set-point will increase water cooled chiller pump speed and thereby the chilled water flow.
The chilled water bypass valve remains closed until any one of the operating chillers flow rate falls below 80% of design (is also user configurable)
Chilled water bypass will also modulate to maintain a minimum safe flow through the chillers.
If the bypass valve is opened 100% and flow rate across the evaporator is less than the minimum flow required, (in case of low loads) pump speed will be ramped up to maintain safe water flow through the water cooled chillers.
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